Lightweight footing for support posts

ABSTRACT

A lightweight footing includes a plastic shell that can be partially filled with a structural foam once placed in final position. The plastic shell can also be shaped to accommodate a steel exoskeleton that increases the load-bearing capacity of the footing significantly.

PRIORITY

This application claims the priority benefit of U.S. Provisional Application No. 62/899,701 filed on Sep. 12, 2019, which are hereby incorporated herein by reference in its entirety.

FIELD

The present invention relates, in general, to building support systems and, more particularly, to a lightweight footing for support posts for houses and buildings.

BACKGROUND

Structures such as homes and buildings are sometimes built on bad soil. Certain types of soils also react differently to loads and moisture content. When the soil under or adjacent to a home or building fails or shrinks, the structure can settle unevenly so that the home or building leans, breaks apart or portions sag. To address this problem, structural posts are often placed under the structure to provide support and leveling.

Concrete footings for structural posts and support beams are typically pre-cast offsite and then transported to the location of installation. Lifting, loading/unloading and moving into position these heavy concrete footings can be time consuming, exhausting and dangerous.

Alternatively, footings can be formed onsite using forms to create pour-in-place footings with concrete mixed onsite. This process is labor intensive. Plus these pour-in-place footings take approximately 3-7 days to cure after pouring the concrete. The long cure time dramatically slows down a project because the workers need to first form the footings and then return days later to the site and place the posts.

Therefore, there is a continuing need for improved construction footings for structural posts and support beams.

SUMMARY

The present invention, in certain embodiments, addresses the drawbacks and weaknesses of the prior art by providing a lightweight footing comprising a plastic shell that can be partially filled with a structural foam once placed in final position. The structural foam is selected for carrying loads.

This lightweight footing provides load-bearing stability for posts in limited access areas such as crawl spaces under homes and also in disaster areas. It eliminates the labor and spaced-apart multi-visit, multi-day process required by conventional pour-in-place concrete footings. The plastic shell can also be shaped to accommodate a steel exoskeleton that increases the load-bearing capacity of the footing significantly.

The disclosure includes a lightweight footing, comprising an open bottom side, a top surface opposing the open bottom side, and a plurality of sidewalls. A first sidewall spans from the open bottom surface to the top surface. A second sidewall opposes the first sidewall and spans from the open bottom side to the top surface. A third sidewall spans from a first lateral edge of the first sidewall to a first lateral edge of the second sidewall. The third sidewall also spans from the open bottom side to the top surface. A fourth sidewall opposes the third sidewall and spans from a second lateral edge of the first sidewall to a second lateral edge of the second sidewall. The fourth sidewall also spans from the open bottom side to the top surface. Each of the first, second, third and fourth sidewalls angle inward such that they converge towards one another as they extend from the open bottom side to the top surface.

Each of the sidewalls can terminate in a top edge vertically above the top surface to define a ridge portion. The top surface can be planar. The plane of the top surface also can be aligned parallel to the open bottom side. An open interior surface can be defined upwardly from the bottom side. The lightweight footing can be shaped as a truncated four-sided pyramid. The lightweight footing can be a singular molded plastic body. The lightweight footing can also include a flange extending horizontally outwardly at the bottom side from each of the sidewalls. The sidewalls can be planar. An access aperture can be defined through the lightweight footing from an outer surface to an inner surface thereof.

The lightweight footing of claim 1 can further include an exoskeleton. The exoskeleton can comprise a horizontal base portion defining a perimeter around each of the sidewalls, a top plate portion disposed atop the top surface, and a plurality of diagonal connector members. Each of the diagonal connector members are disposed along the intersecting lateral edges of each of the sidewalls. Each of the diagonal connector members can be secured at respective opposing ends thereof to the base portion and the top plate portion.

The disclosure also includes a structure reinforcement system. The system can comprise a molded plastic shell and a load bearing foam disposed in the open interior of the molded plastic shell. The molded plastic shell can comprise an open bottom side defining an open interior, a top surface opposing the open bottom side, a first sidewall spanning from the open bottom surface to the top surface, a second sidewall opposing the first sidewall and spanning from the open bottom side to the top surface, a third sidewall spanning from a first lateral edge of the first sidewall to a first lateral edge of the second sidewall, and the third sidewall spanning from the open bottom side to the top surface, and a fourth sidewall opposing the third sidewall, the fourth sidewall spanning from a second lateral edge of the first sidewall to a second lateral edge of the second sidewall, and the fourth sidewall spanning from the open bottom side to the top surface. Each of the sidewalls converge towards one another as they extend from the open bottom side to the top surface.

A support post can be disposed atop the top surface. An exoskeleton can be provided to an exterior surface of the molded plastic shell. An access aperture can be defined through the plastic shell from an exterior surface thereof to the open interior, wherein an access path is defined through the load bearing foam from the access aperture to the open bottom side.

The disclosure further includes a method of supporting a structure. The method can include placing a molded plastic shell atop a portion of soil such that the molded plastic shell is aligned under a portion of the structure that requires support, injecting a load bearing foam into the molded plastic shell through an access aperture defined through the molded plastic shell, and placing a support post atop a top surface of the molded plastic shell.

An exoskeleton can be provided to an exterior surface of the molded plastic shell. The load bearing foam can be injected until the load bearing foam consolidates the soil below the molded plastic shell. A portion of earth can be excavated to define the portion of soil upon which the molded plastic shell is placed. A vertical height of the support post can be adjusted.

The above summary is not intended to limit the scope of the invention, or describe each embodiment, aspect, implementation, feature or advantage of the invention. The detailed technology and preferred embodiments for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations or in isolation, without departing from the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top perspective view of a lightweight footing in accordance with embodiments of the present invention.

FIG. 2 is a side view of a lightweight footing in accordance with embodiments of the present invention.

FIG. 3 is a top view of a lightweight footing in accordance with embodiments of the present invention.

FIG. 4 is a side view of a lightweight footing with a metal exoskeleton in accordance with embodiments of the present invention.

FIG. 5 is a top view of the plastic shell of a lightweight footing with a metal exoskeleton in accordance with embodiments of the present invention.

FIG. 6 is a bottom perspective view of a lightweight footing in accordance with embodiments of the present invention.

FIG. 7 is a side cross-sectional illustration of the lightweight footing in its installed position in accordance with embodiments of the present invention.

FIG. 8 is another side cross-sectional illustration of the lightweight footing in its installed position in accordance with embodiments of the present invention.

DETAILED DESCRIPTION

In the following descriptions, the present invention will be explained with reference to various example embodiments; nevertheless, these embodiments are not intended to limit the present invention to any specific example, environment, application, or particular implementation described herein. Therefore, descriptions of these example embodiments are only provided for purpose of illustration rather than to limit the present invention. The invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

The various features or aspects discussed herein can also be combined in additional combinations and embodiments, whether or not explicitly discussed herein, without departing from the scope of the invention.

Exemplary embodiments of a lightweight footing 100 are depicted in FIGS. 1-8. The footing 100 defines a hollow plastic shell or body 102 that generally resembles a truncated four-sided pyramid. As such, the shell 102 defines an open bottom surface 104, a top surface 106 and four side surfaces 108 a, 108 b, 108 c and 108 d. The side surfaces angle inward as they extend upward from the bottom surface or base 104 and terminate once reaching the top surface 106 (or shortly thereafter). The top surface 106 is planar so that the beam can rest atop the top surface 106 in a stable manner. The bottom surface 104 defines a flange 105 extending outwardly of the perimeter of the sides and having an open interior 107 (see FIG. 6) that can be filled with foam or other fill material 109.

One or more of the side surfaces 108 a, 108 b, 108 c and 108 d define an access aperture 110 into the interior of the shell 102 that allows the user to fill the interior of the shell with foam or other fill material 109.

It can also be seen in the figures that the top edges of the side surfaces 108 a, 108 b, 108 c and 108 d terminate vertically above the top surface 106. This arrangement defines a ridge portion 111 at the perimeter of each of the four sides of the top surface 106. The ridges 111 are beneficial to ensure that the support post is centered atop the shell during the installation process. Owing to the ridges 111, the support post is also less likely to migrate laterally due to earthquake activity.

FIGS. 4-5 show the same shell 102 in the same views as FIGS. 2-3, but in FIGS. 4-5 a metal exoskeleton 112 has been provided to the exterior of the shell 102. The metal exoskeleton 112 increases the weight bearing capacity of the shell. The exoskeleton 112 comprises a horizontal base portion 114 that defines a perimeter around all four sides of the shell 102. A top plate portion 116 is disposed atop the top surface 106. A diagonal connector member 118 is provided to each of the four edges where two sides intersect. The diagonal connector members 118 are secured at respective opposing ends by the base portion 114 and top plate portion 116. The exoskeleton defines a truncated triangle in side view as can be seen in FIG. 4.

Referring now to FIGS. 7-8, the use of the footing 100 to support a building structure will now be described. If necessary, the user first excavates 120 the area where the footing will be placed. The user then smooths out the soil in the location where the footing will be placed. Plastic sheet or other substrate can be placed atop the soil, if desired. Then the plastic shell 102 is set in place.

If an exoskeleton is used, then the exoskeleton 112 is either pre-installed on the shell or the user places the exoskeleton 112 over the shell prior to the post installation step. Adhesive can be applied to secure the exoskeleton 112 to the outer surface of the shell 102.

Next, the support post 122 is installed atop the top surface 106 of the shell 102 such that the post 122 is located under the building's beam 124 that needs support. The floor joists 126 are also indicated for spatial reference. The post 122 can be adjustable for height or can be any other type of adjustable or non-adjustable support post used to support buildings or structures.

Next, the user injects load-bearing foam 109 into the interior of the shell 102 through the access apertures 110 until the foam completely fills the open interior 107 of the shell 102 and also consolidates the soil 128 located underneath the shell 102.

The load bearing foam 109 can be a polymer material that expands into a load-bearing structure upon injection. In particular, the load bearing foam 109 can be a commercially-available high-density structural foam. For example the foam can have a 10-pound density value, which has been found by the Applicant to hold more weight than typical ordinary soil would hold. Other foam or fill materials can also be used where such material will provide the necessary rigid support and load-bearing capacity.

The open interior 107 of the shell 102 can also be partially filled with foam prior to installation. To do this, the shell 102 is inverted and filled so that the foam extends from the top surface to approximately 80-90% of the vertical height of the shell. The advantage of this step is to minimize the volume of foam material that the user must inject into the shell in the installation step described above. It is necessary to also drill out or otherwise provide a path from the access apertures 110 to the unfilled volume of the shell so that the foam can be injected through the access apertures 110 and reach the unfilled portion of the shell adjacent to the soil 128.

The footing, support system and methods described above allow the support post to be placed below a beam or other structure adjacent to a sag in the building floor such that the sag is fixed in one single visit and with a minimum of labor and danger.

The unfilled shells 102 can be easily nested into one another when stacked so that they can be transported easily and consume minimal storage space.

The shells can be formed using typical plastic injection molding techniques and materials.

While the invention has been described in connection with what is presently considered to be the most practical and preferred example embodiments, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed example embodiments. It will be readily apparent to those of ordinary skill in the art that many modifications and equivalent arrangements can be made thereof without departing from the spirit and scope of the present disclosure, such scope to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products.

For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim. 

What is claimed is:
 1. A lightweight footing, comprising: an open bottom side; a top surface opposing the open bottom side; a first sidewall spanning from the open bottom surface to the top surface; a second sidewall opposing the first sidewall and spanning from the open bottom side to the top surface; a third sidewall spanning from a first lateral edge of the first sidewall to a first lateral edge of the second sidewall, and the third sidewall spanning from the open bottom side to the top surface; and a fourth sidewall opposing the third sidewall, the fourth sidewall spanning from a second lateral edge of the first sidewall to a second lateral edge of the second sidewall, and the fourth sidewall spanning from the open bottom side to the top surface, wherein each of the first sidewall, the second sidewall, the third sidewall and the fourth sidewall angle inward such that they converge towards one another as they extend from the open bottom side to the top surface.
 2. The lightweight footing of claim 1, wherein each of the first sidewall, the second sidewall, the third sidewall and the fourth sidewall terminates in a top edge vertically above the top surface to define a ridge portion.
 3. The lightweight footing of claim 1, wherein the top surface is planar.
 4. The lightweight footing of claim 1, wherein the top surface is a planar surface aligned parallel to the open bottom side.
 5. The lightweight footing of claim 1, further comprising an open interior surface defined upwardly from the bottom side.
 6. The lightweight footing of claim 1, wherein the lightweight footing is shaped as a truncated four-sided pyramid.
 7. The lightweight footing of claim 1, wherein the lightweight footing comprises a singular molded plastic body.
 8. The lightweight footing of claim 1, further comprising a flange extending horizontally outwardly at the bottom side from each of the first sidewall, the second sidewall, the third sidewall and the fourth sidewall.
 9. The lightweight footing of claim 1, wherein each of the first sidewall, the second sidewall, the third sidewall and the fourth sidewall are planar.
 10. The lightweight footing of claim 1, further comprising an access aperture defined through the lightweight footing from an outer surface to an inner surface thereof.
 11. The lightweight footing of claim 1, further comprising an exoskeleton, the exoskeleton comprising: a horizontal base portion defining a perimeter around each of the first sidewall, the second sidewall, the third sidewall and the fourth sidewall; a top plate portion disposed atop the top surface; and a plurality of diagonal connector members, each of which are disposed along each of the first lateral edge of the first sidewall, the first lateral edge of the second sidewall, the second lateral edge of the first sidewall and the second lateral edge of the second sidewall, wherein each of the diagonal connector members are secured at respective opposing ends thereof to the base portion and the top plate portion.
 12. A structure reinforcement system, comprising: a molded plastic shell, comprising: an open bottom side defining an open interior; a top surface opposing the open bottom side; a first sidewall spanning from the open bottom surface to the top surface; a second sidewall opposing the first sidewall and spanning from the open bottom side to the top surface; a third sidewall spanning from a first lateral edge of the first sidewall to a first lateral edge of the second sidewall, and the third sidewall spanning from the open bottom side to the top surface; and a fourth sidewall opposing the third sidewall, the fourth sidewall spanning from a second lateral edge of the first sidewall to a second lateral edge of the second sidewall, and the fourth sidewall spanning from the open bottom side to the top surface, wherein each of the first sidewall, the second sidewall, the third sidewall and the fourth sidewall angle inward such that they converge towards one another as they extend from the open bottom side to the top surface; and a load bearing foam disposed in the open interior.
 13. The structure reinforcement system of claim 12, further comprising a support post disposed atop the top surface.
 14. The structure reinforcement system of claim 12, further comprising an exoskeleton provided to an exterior surface of the molded plastic shell.
 15. The structure reinforcement system of claim 12, wherein an access aperture is defined through the plastic shell from an exterior surface thereof to the open interior, wherein an access path is defined through the load bearing foam from the access aperture to the open bottom side.
 16. A method of supporting a structure, comprising: placing a molded plastic shell atop a portion of soil such that the molded plastic shell is aligned under a portion of the structure that requires support; injecting a load bearing foam into the molded plastic shell through an access aperture defined through the molded plastic shell; and placing a support post atop a top surface of the molded plastic shell.
 17. The method of claim 16, further comprising providing an exoskeleton to an exterior surface of the molded plastic shell.
 18. The method of claim 16, wherein the load bearing foam is injected until the load bearing foam consolidates the soil below the molded plastic shell.
 19. The method of claim 16, further comprising excavating a portion of earth to define the portion of soil upon which the molded plastic shell is placed.
 20. The method of claim 16, further comprising adjusting a vertical height of the support post. 